Manuplas Subsea Buoyancy & Moulded Products Brochure 2018

ManuplasÂŽ Subsea Buoyancy & Moulded Products Impact and abrasion protection for a range of applications across the subsea oil and gas, marine and renewables industries

02 |

Manuplas®

Better products for challenging situations For further information about the Manuplas® range of products, please visit www.advancedinsulation.com

Oil & Gas

Marine

Manuplas® | Subsea Buoyancy and Moulded Products

Renewables

| 03

Contents 04 05 07 08 10 12 15 16

Subsea Buoyancy & Moulded Products Designed to Protect, Built to Last Installation Buoys Modular Buoys Pipe Laying Floats Modsyn Subsurface Buoys Umbilical Floats ROV Buoyancy

18 20 21 22 23 24 25 26

Distributed Buoyancy Modules Grommet Clamps Cable Protection Banding Solutions In-house Testing Facilities Applications - Buoyancy & Moulded Products Single Source Solutions Provider Global Presence

Find out more about ManuplasÂŽ at: www.advancedinsulation.com

04 |

Manuplas®

Subsea Buoyancy & Moulded Products Advanced Insulation’s Manuplas® division offer a range of market leading subsea buoyancy solutions alongside moulded polyurethane products which offer subsea impact and abrasion protection Installation Buoyancy:

Engineered Buoyancy:

Manuplas buoyancy products are used to assist offshore installation of pipelines and subsea equipment.

Manuplas® supply buoyancy products designed to survive for the life of the field whilst delivering market leading technical performance. In floating production scenarios, buoyancy is used to configure subsea systems, mitigating unwanted loads and stresses. Products include:

®

Comprising a low density foam core protected by a durable polyethylene shell, Manuplas® buoys are engineered and tested to withstand the harshest handling and hydrostatic operating conditions, whilst delivering the highest technical performance.

The product range includes:

++

Umbilical floats

++

ROV buoyancy

++

Distributed buoyancy

++

General purpose installation buoys

++

Modular buoys

Total Solutions Provider

Water Depths >3000msw

++

Pipe laying floats

Manuplas® Buoyancy can be offered

Syntactic lightweight foam

++

Modsyn floats

alongside ContraTherm® insulation

buoyancy materials

Manuplas® | Subsea Buoyancy & Moulded Products

| 05

Manuplas®

Designed to Protect, Built to Last Manuplas® buoyancy and protection products are manufactured with long lasting, durable and high performance materials Cable & Pipeline Protection Products:

Clamping Solutions:

Manuplas® offer products to provide protection in the harshest operating environments for scenarios where impact, abrasion and over-bending would be catastrophic.

Manuplas® supply clamping solutions which are adaptable to a wide range of carrier pipe applications:

++

Manuplas’ modular interlocking tubular cable protection product is designed to protect cables or pipelines from abrasion and impact.

++

For more complex requirements, Advanced Insulation offer its C.Shield® Cable Protection System (CPS) where key components include a Bellmouth, Latch Assembly and J-Tube Connector, Hybrid Bend Limiter and Impact Protection.

++

Compliant clamps

++

Grommet clamps

In addition Advanced Insulation provide a C.Shield® Atlas Piggyback System (PBS) Atlas Piggyback System Ask for a C.Shield® PBS brochure for more C.Shield® CPS Ask for a C.Shield® CPS brochure for more

Find out more about Manuplas® at: www.advancedinsulation.com

06 |

ManuplasÂŽ | Subsea Buoyancy & Moulded Products

| 07

Manuplas速

Installation Buoys Manuplas速 subsea installation buoys are designed to provide a general purpose solution to subsea buoyancy 100kg Installation Buoy

Overview: The Manuplas速 range of subsea installation buoys are available in standard sizes: 100kg, 250kg and 500kg with a choice of dimensions.

Features: ++

Ropes

++

Various through hole arrangements or pad eyes top and bottom

++

Rotary moulded polyethylene shell

++

Cast syntactic foam core with a specification to suit the water depth

500kg Installation Buoy

Range of Water Depths

Bespoke Sizes Available

Ratings up to 3000msw available

Customised to suit your project requirements

Find out more about Manuplas速 at: www.advancedinsulation.com

08 |

Manuplas速

Modular Buoys Manuplas速 modular buoyancy is a customisable product providing support for mooring systems from surface to 3000msw Overview:

Construction:

Manuplas速 supply modular buoyancy units in three industry standard sizes:

++

The flotation core component may be syntactic foam for deepwater deployment or more lightweight expanded polymer foams to maximise buoyancy yield in shallow waters

++

Cast with a robust impact resistant rotationally moulded external finish

++

MINI - 1750mm x 1750mm CrossSection

++

MID - 2350mm x 2350mm CrossSection

++

MAX - 3000mm x 3000mm CrossSection

Individual buoyancy elements or complete buoys including central structural steelwork assemblies are also available and can be supplied with a variety of handling options.

Applications: ++

Suspended mooring

++

Equipment installation

++

General offshore operations

Manuplas速 | Subsea Buoyancy & Moulded Products

| 09

MINI Modular Buoy Features and Benefits: ++

Modular design, 1-40T of nett buoyancy

++

MINI, MID and MAX industry standard sizes

++

Compartmentalised design for greater protection

++

Flat sides to facilitate stable storage and tight operational configurations

++

Central structural steelwork

++

Lightweight foam flotation cores

MID Modular Buoy

Interlocking Design To eliminate rotation during operation Easily Adjustable To meet specific buoyancy requirement Easy to Repair Easy buoyancy element change-out if damaged MAX Modular Buoy Find out more about ManuplasÂŽ at: www.advancedinsulation.com

10 |

Manuplas®

Pipe Laying Floats Manuplas® offer a number of pipe laying float solutions tailored to fit a customer’s specific requirements Overview: Pipe laying floats are used as temporary buoyancy modules strapped to a pipeline to reduce tension and weight in the pipeline during the installation process for surface or deepwater pipeline installation applications.

Configurations: ++

++

Single piece unit configured with an open through hole or with a through chain and shackle to assist with handling operations Modular float consisting of multiple individual units secured together with a central through pipe complete with pad eyes each end

Features: ++

Robust and impact resistant rotationally moulded external shell

++

Lightweight foam flotation core

++

Interlocking spigot and cuff options

Manuplas® | Subsea Buoyancy & Moulded Products

Modular Design Number of modules adjusted to suit project Versatile Configuration Accommodates all subsea pipeline diameters Integral Strap Grooves Easy access/quick release by divers & ROVs Easy to Replace Damaged modules at minimal cost

| 11

Construction: Modular Float configurations consist of multiple individual units secured together with a central through rigid bar complete with pad eyes each end.

PUSAD: Rotary Moulded Polyethylene (PE) Shell, Polyurethane (PU Foam Filled Core) ++

Cost effective

++

Modular configuration enabling adjustment to suit project

++

Easily replaceable if damaged

++

Shallow depths down to 250msw

EPSAD: Closed Cell Expanded Polymer (EP) Saddles c/w PU Elastomer Sprayed Skin ++

Lightweight & consistent foam

++

Low water absorption

++

Sprayed with durable polyurethane elastomer skin – impact/abrasion resistant

++

Variety of lengths available to suit buoyancy needs

++

Density can be varied to suit the required depth rating

Single Piece Custom Floats SYNSAD: Rotary Moulded Polyethylene (PE) Shell, Syntactic Foam Core ++

High performance

++

Modular configuration enabling adjustment to suit project

++

Easily replaceable if damaged

++

Range of densities available to suit required depth rating

++

Deep water installation from 500msw – 3000msw

++

Depending on preferred handling methods, single piece units can be configured with an open through hole, a through chain and shackle assembly or a rigid central pipe with pad eyes each end.

++

In the event of a low volume or bespoke requirement alternative materials are available.

++

Cross-section dimensions sized to best suit shipping by container

Banding Options Carbon Steel, Inconel Stainless Steel & SMART Bands

Find out more about Manuplas® at: www.advancedinsulation.com

12 |

Modsyn 29

Manuplas®

Modsyn Subsurface Buoys Manuplas® modsyn subsurface buoys provide a solution for subsea buoyancy where small amounts of tethered buoyancy are required Overview:

Applications:

Modsyn buoys are available in three standard sizes with a range of depth ratings available from surface to 3000msw.

++

Umbilical and cable support

++

Installation aids

++

Trimming buoyancy

Modsyns can be configured with either a central through hole or with fixed eye top and bottom.

Features:

Construction: ++

Tough impact/abrasion resistant rotationally moulded polyethylene shell

++

High performance composite syntactic foam core

++

Internal through hole Ø40mm

++

Options: galvanised metalwork

Modsyn 59

++

Durable high quality construction

++

Rotary moulded polyethylene skin formulated to provide UV resistance

++

Simple to attach through central hole using steelwork or ties

++

Colour coding available for depth identification

++

Optional in-moulded graphics

++

Recessed lifting slots for ease of use

Cost Effective Solution

Improves Onboard Safety

For a wide variety of subsea operations

Flat surface to assist stability & handling

Modsyn 105 Manuplas® | Subsea Buoyancy & Moulded Products

| 13

Find out more about ManuplasÂŽ at: www.advancedinsulation.com

14 |

ManuplasÂŽ | Subsea Buoyancy & Moulded Products

| 15

Manuplas速

Umbilical Floats Manuplas速 offer a two-piece wrap around flotation module for cables and control umbilicals

Manuplas速 Umbilical Floats can be used in combination with ROVs to maintain the necessary length of umbilical buoyancy below the surface or general umbilical requirements for cable or hose buoyancy.

Features:

The floats are in two halves with an integral elastomer clamp assembly, configured to the outside diameter of the cable / umbilical with water depth ratings available from surface to 3000msw.

++

Two-piece purpose built flotation modules

++

Strapping location grooves incorporated

++

Polyurethane elastomer / steel clamp construction

++

Optional customer graphics

++

Axial load testing capability

Construction:

Easy Assembly / Install

The flotation core may be high performance syntactic foam for deepwater deployment or more light weight expanded polymer foams to maximise buoyancy yield in shallower waters. The core may be cast with a rotationally moulded outer skin or a tough and durable sprayed elastomer.

Due to overcentre latch fastening option

High Performance Lightweight foam flotation core

Find out more about Manuplas速 at: www.advancedinsulation.com

16 |

Manuplas®

ROV Buoyancy Manuplas® offer a range of composite foam ROV buoyancy blocks for use in operating depths down to 6000msw. Available for Manned, Autonomous and Remote Operated Vehicles Construction: ++

++

++

++

PVC based copolymer foams are traditionally used for shallow water (<600msw) deployment, where as pure syntactic foams available in low density variants are used for depths down to 6000msw Composite syntactic foam core comprising injection moulded macrospheres encapsulated within a polyurethane based syntactic foam matrix The buoyancy blocks are laminated and then machined into customised complex shapes as required using inhouse CNC machining facilities, enabling a fast turnaround from bespoke design to delivery.

A light stable and wear resistant polyurethane based elastomer external coating is applied to the client colour and surface finish specifications.

Manuplas® | Subsea Buoyancy & Moulded Products

++

Alternatively pure syntactic foam blocks can be manufactured using high strength thermosetting resin incorporating hollow glass microspheres

Features: ++

Lightweight Low Density and Ultra-low density syntactic foam cores provide exceptional buoyancy and enable reliable operational performance at deeper depths

++

High performance polyurethane elastomer coating and light stable topcoat Bespoke Design & Build To meet specific project requirements

In-House Tooling

Range of Options

CNC facility for tight controls of quality

Surface finishes and customer graphics

| 17

Find out more about ManuplasÂŽ at: www.advancedinsulation.com

18 |

Manuplas®

Distributed Buoyancy Modules Manuplas® offers distributed buoyancy for reducing tension load on subsea risers and umbilicals Overview:

Clamping Technology:

Manuplas® manufacture buoyancy and ballast modules complete with appropriate clamping systems engineered to suit each riser scenario.

These are known as Distributed Buoyancy Modules (DBMs).

Each module must be located using an internal clamp at specific points along the riser length with no risk of slippage throughout its operational lifetime.

In compliant riser systems, which utilise rigid or flexible lines, DBMs are employed to create an optimised configuration (e.g. Lazy or Steep wave) to relieve damaging tensions loads, enabling a long design life (25 years) despite arduous offshore conditions.

Type Approval API17L1 Industry recognised type approval of DBM Clamp

On Steel Catenary Risers it is often possible to utilise large clamping loads without any detrimental effect to the riser itself, employing steel or other more exotic alloys. However this is not possible without insulated or multi-layered risers possessing a softer clamping surface. In such cases, traditional clamps can be too stiff to cope with geometric contractions and the riser maybe damaged by such attachment - Manuplas® compliant clamp technology mitigates this problem with an innovative interface.

Manuplas® | Subsea Buoyancy & Moulded Products

| 19

The two main elements to a DBM:

2. External Buoyancy Element:

1. The Internal Clamp Assembly:

++

The buoyancy unit core is designed to withstand the hydrostatic loads applicable at the specified water depth rating

++

Durable, long lasting polyethylene shell which is highly impact and abrasion resistant

++

High performance material which is resilient to seawater, UV exposures and fracture

++

Versatile configuration can accommodate all subsea riser and umbilical diameters

++

Can be designed with integral VIV strakes to provide a cost effective anti vibration solution.

++

Low maintenance design

++

Safe and simple installation and release

++

Long design life (25 years) in challenging offshore conditions

++

Customised specifications to suit customer’s unique application

++

Optional customer graphics

++

++

++

Clamps can vary from integral rubber fingers, to polyurethane grommet clamps to the compliant clamp depending on loading requirements.

Rubber inserts form a friction grip against the flexible riser and increase surface contact between the rubber insert and flexible riser/ umbilical.

Single, double and triple clamp fastener arrangement methods are available depending on load conditions with a single clamp capable of holding a 2000kg uplift DBM.

Installation: For ease of installation, Manuplas® supply DBMs to site with all components of the clamp assembled, leaving the clamp in a hinge position with only one holding bolt remaining to completely fit the clamp onto the flexible riser.

Find out more about Manuplas® at: www.advancedinsulation.com

20 |

Manuplas®

Grommet Clamps Manuplas® offer a grommet clamp designed to provide improved containment and centralizing of umbilicals and pipelines and protect the rope or cable passed through it Applications:

Construction:

++

Offshore new pipeline installation

++

++

Offshore retro-fit pipelines, risers and jumpers

++

Offshore wind farm marine cabling

The clamp is moulded from high performance marine grade cast polyurethane elastomer to allow sufficient grip during operation

++

Through bolt holes

Features and Benefits: ++

Safe, simple and fast installation

++

Can be configured with multiple straps/bands for all performance requirements

++

Can be installed by subsea divers

++

Designed for project lifetimes

One-Fit Solution

Cast Mould Manufacture

Resilient Materials

Single design for multiple project requirements

Ensure parts conform to tight geometric tolerances

Seawater, UV exposures and fracture

Manuplas® | Subsea Buoyancy & Moulded Products

| 21

Manuplas®

Cable Protection

Manuplas® offer modular interlocking tubular cable protection designed to protect cables or pipelines from abrasion and impact Construction:

Features:

++

++

Tough, impact & abrasion resistant

++

Interlocking moulding design assists in ease of installation

++

Neutrally buoyant in seawater

++

Non-marking material

++

++

Interlocking modules moulded in high performance polyurethane elastomer In-house CNC machining facility enables fast production of prototype and production tooling to reduce lead times Integral strap grooves are incorporated to house all types of metallic or polymeric strapping.

Manuplas® can assist in the supply and specifications of the strapping most appropriate for the installation and service conditions.

C.Shield® Advanced Cable Protection System (CPS): Advanced Insulation also offers its C.Shield® CPS which includes a Bellmouth, Latch Assembly, J-Tube Connector, Hybrid Bend Limiter and Impact Protection.

C.Shield® Advanced CPS Ask for the C.Shield® CPS Brochure for more

Find out more about Manuplas® at: www.advancedinsulation.com

22 |

Manuplas®

Banding Solutions Manuplas® offer a range of metal banding options which can be used with products including pipe laying floats, umbilical floats, piggyback saddles and cable protection The banding options offered by Manuplas® include:

High Tensile Strength Reliable and long lasting

++ Carbon Steel ++ Grade 316 Stainless Steel ++ Monel

Cost Effective

++ Inconel

And straightforward to install

Manuplas® is also able to offer an alternative polymeric strapping system which incorporates a single buckle, is fully non-corrosive and very easy to install: ++ HCL Smartband Manuplas® can provide fully comprehensive installation advice and support and can provide installation tooling.

Smart® Band is a registered trademark of HCL Fasteners Ltd.

Manuplas® | Subsea Buoyancy & Moulded Products

Corrosion Resistant Ideal for harsh subsea conditions

| 23

ManuplasÂŽ

In-house Testing Facilities

ManuplasÂŽ have a comprehensive range of in-house testing facilities to ensure optimum product performance Deep Water Testing Hydrostatic test chamber rated to 300 Bar

Shallow Water Testing Hydrostatic test chamber rated to 100 Bar

Macrosphere Testing Testing cells rated to 700 Bar

Find out more about ManuplasÂŽ at: www.advancedinsulation.com

24 |

Manuplas®

++ Offshore operations

++ Subsea installation

++ Umbilical support

++ Steel catenary risers

++ Cable protection

++ Flexible risers and umbilicals

++ Offshore wind farm marine cabling

Oil & Gas

Marine

Renewables

Manuplas® | Subsea Buoyancy & Moulded Products

es

g lin Cab

++ Offshore pipelines

lation stal

Farm Wind

Manuplas® subsea buoyancy and moulded products can be applied to a wide range of applications across the subsea oil and gas, marine and renewables industries

b Su

a In se

Offsho re P ipe li n

Applications for Subsea Buoyancy & Moulded Products

Of fsh o

re O

pera tions

| 25

Manuplas®

Single Source Solutions Provider

Steel C aten ary Ris er s

x ib Fle

& les Um b

Ca ble Pro tect i on

ilicals

Su cal Umbili

s

ort pp

Advanced Insulation offer a cost-effective solution for subsea oil and gas projects by providing a full package of products alongside Manuplas® buoyancy and moulded products.

Manuplas® Buoyancy

ContraTherm®

Installation and engineered buoyancy

Syntactic flexible subsea insulation

Clamping Solutions

C.Tag® Markers

Piggyback, compliant & grommet clamps

High visibility underwater markers

Cable Protection

C-Ling®

Bend stiffeners & J-tube seals

Offshore wind farm anti-corrosion solution

Find out more about Manuplas® at: www.advancedinsulation.com

26 |

Manuplas®

Global Presence

9.

Advanced Insulation is a marketleading insulation provider with global reach Advanced Insulation’s Manuplas trading division offers a fully comprehensive service that includes survey, design, manufacture, application and technical support.

8.

Requests for quotation and marketing enquiries should be submitted to: sales@manuplas.co.uk With branches across the world, the company can offer organisations and businesses a comprehensive array of products including buoyancy, cable protection systems, subsea and topside insulation, subsea markers, fendering systems, passive fire protection, cryogenic spill protection and blast and fire walls.

A full technical support service is available for all products, at any location.

Design

Manufacture

Installation

Manuplas® | Subsea Buoyancy & Moulded Products

3.

| 27

Manufacturing Facilities Design, manufacture, technical support & sales

GLOBAL SALES OFFICES: 1. United Kingdom Unit 18 Estover Road Estover Plymouth PL6 7PY

1.

United Kingdom Quedgeley West Business Park Bristol Road Gloucester GL2 4PA

Tel: +44(0)1752 771740 Tel: +44(0)1452 880880 4.

5.

7.

6.

2.

2. Angola Rua Direita do Gamek N26 Base Kubics Largo Corimba-Samba Luanda

3. Brazil Rodovia SP 107, km 29 Jaguariúna – SP Caixa Postal 255 13820-000

Tel: +244923 364 273

Tel: +55 19 41417117

4. Kazakhstan 184/1 Iksanova St., 090300, Burlin region, Aksai West Kazakhstan Oblast

5. South Korea 72-1 Sinsan-Ro Saha-gu Busan 49434

Tel: +7 701 786 9158

Tel: +82 51 921 6367

6. Malaysia 56 Jalan Anggerik Vanilla Canal Garden Kota Kemuning Shah Alam 40460

7. United Arab Emirates P. O. Box 18512 Jebel Ali Free Zone Dubai Tel: +971 4 8819821

Tel: +603 5121 3886 8. USA 11490 Westheimer Road #925 Houston, TX 77077

9. Canada 121 Germain Street Saint John, NB E2L 2E9

Tel: +713 425 6320

Tel: +1 (780) 905 4723

Find out more about Manuplas® at: www.advancedinsulation.com

Advanced Insulation Quedgeley West Business Park Bristol Road, Hardwicke Gloucester GL2 4PA Tel: +44(0)1452 880880 Email: sales@manuplas.co.uk www.advancedinsulation.com